Direct attach or surface mount LEDs are mounted onto a flat, thermally conductive, substrate, which is folded to form a light recycling cavity. A planar substrate is first coated with a metal layer, which is patterned to electrically connect the LEDs. The direct attach or surface mount LEDs are mounted on the substrate. The substrate is then scribed on the backside to form cut channels which form the folds. The direct attach or surface mount LEDs are then attached onto the metal layer on the substrate. The substrate is then folded into a light recycling cavity where the direct attach or surface mount LEDs are facing the inside of the cavity.